US5545484A - Heat and oxidation resistive high strength material and its production method - Google Patents

Heat and oxidation resistive high strength material and its production method Download PDF

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US5545484A
US5545484A US08/351,705 US35170594A US5545484A US 5545484 A US5545484 A US 5545484A US 35170594 A US35170594 A US 35170594A US 5545484 A US5545484 A US 5545484A
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heat
zro
high strength
coating
strength material
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Shizuka Yamaguchi
Yoshitaka Kojima
Sai Ogawa
Hideyuki Arikawa
Mitsuo Haginoya
Yukihiko Wada
Kyozo Iwao
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Hitachi Ltd
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Hitachi Ltd
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/08—Oxides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/30—Self-sustaining carbon mass or layer with impregnant or other layer

Definitions

  • the present invention relates to a heat and oxidation resistive high strength material used in structural body pans subject to bleaching in high temperature/oxidative atmosphere, the body structure of an orbital space plane, a combustor, the combustor for a gas turbine, a blade, and a nozzle; the present invention also relates to a method for producing the heat and oxidation resistive high strength material.
  • heat resistive materials there are metallic materials, composite materials, and ceramics to name a few.
  • heat resistive alloy there is a super alloy which has Ni, Co, and Fe as the constituent bases.
  • Ni the main constituent of a Ni-based super alloy, has a melting point of 1455° C., and therefore, this alloy cannot be used in an environment with temperature range that goes beyond this point. For this reason, an environmentally induced damage insulation layer is formed on the surface of this alloy.
  • a thermal barrier coating (TBC) method which involves spraying melted ceramics of ZrO 2 and Y 2 O 3 into the middle layer of a super alloy, produced with the purposes of relaxing thermal stress, improving adhesion, enhancing oxidation resistance, and improving anti-corrosion at the surface.
  • JPA62-156938 describes a functionally gradient material (FGM) which relaxes thermal stress by having the composition ratio of ZrO 2 and Y 2 O 3 change continuously at the middle layer between the substrate and the ceramics.
  • FGM functionally gradient material
  • intermetallic compound and a high melting point metal.
  • intermetallic compounds as a heat resistive structure are Al compounds of iron family (Fe, Ni, Co) and Ti, but these compounds leave some room for improvement in terms of hardness, workability, and resistive to oxidation.
  • the high melting point metals of W, Mo, Nb, Ta etc. have high thermal conduction and has good resistance against heat but has a weakness of being abraded easily by oxidation; and therefore, there is a need to develop an alloy having strength and resistance to oxidation or a surface process which imparts these characteristics.
  • composite materials which have heat resistancy and high strength.
  • Composite materials having high strength fibers at a high temperature range improve the strength of matrix materials at a high temperature range.
  • matrix types there are fiber reinforced plastics (FRP), fiber reinforced metals (FRM), fiber reinforced ceramics (FRC), and carbon fiber reinforced carbons (CFRC).
  • FRP fiber reinforced plastics
  • FRM fiber reinforced metals
  • FRC fiber reinforced ceramics
  • CFRC carbon fiber reinforced carbons
  • Limit on the highest usable temperature depends on the type of matrix used. For the plastic type, the temperature is 300° C.; for the metal type, 1300° C.; for the ceramic type, 1800° C.; and for the carbon type, 3000° C. approximately.
  • the density of the CFRC is less than 2.0 and the strength of this material does not deteriorate until over 300° C.; the material is known as a super heat resistive material for retaining excellent strength and excellent hardness at high temperatures.
  • the CFRC is made of carbon only, in the oxidative atmosphere of around 500° C., oxidative abrasion becomes noticeable. Therefore, this material cannot be used at temperatures above 500° C. in an environment of oxidative atmosphere. Therefore, in order to use the CFRC even in such an environment, an anti-oxidation treatment becomes necessary. That is, the determining factor of the usable heat resistive temperature of the CFRC in the oxidative atmosphere is the durability of the anti-oxidation treatment.
  • An example of the anti-oxidation treatment is an anti-oxidation coating formed on the substrate surface.
  • One of the main coating elements of the anti-oxidation coating is SiC.
  • SiC For forming SiC, there are a chemical vapor reaction (CVR) method or a chemical vapor deposition (CVD) method.
  • CVR chemical vapor reaction
  • CVD chemical vapor deposition
  • the CVR method involves diffusing metallic silicon vapor into the substrate and reacting with the carbons in the substrate to form SiC. Passages are required for producing this reaction, and because holes are very difficult to get rid of, the coating is left with many holes. In the oxidative atmosphere, oxygen enter into the substrate through these holes and cause damages, and therefore, there is the oxidation problem.
  • the CVD method involves forming a coating by depositing a coating at the atomic level, SiC with very high purity and a very fine crystal structure can be formed.
  • TEOS tetraethyl orthosilicate
  • the anti-oxidation surface of the C/C material a material of metallic layers consisting of a hafnium, tantalum or zirconium foil between the rhenium or silicon carbite layers is described in JPA1-23048 No. 7 of "Heat and Oxidation Resistive Reinforced Material and its Production Method.”
  • the anti-oxidation coating layer of this materials reacts, in the oxidative atmosphere at 2000° C., under certain combination of materials to produce products that possibly lower the anti-oxidation property.
  • high temperature anti-resistive carbon materials having a silicon carbite film formed on top of the carbon substrate, and Hf and Zr metal films formed on top of the silicon carbite film, and an Ir film formed on top of this is disclosed in JPA4-149083.
  • SiC which is used often as a heat and oxidation resistive coating layer formed on the substrate surface, is oxidized to SiO 2 in the high temperature range, and higher the temperature, more of this product forms. Additionally, as heating and cooling is repeated, the oxidized coating of SiO 2 is subject to peeling and therefore, durability cannot be achieved.
  • the limit on the usable temperature of SiC as a heat and oxidation resistive coating layer is 1700° C.
  • the purpose of the present invention is to solve the aforementioned problems of the prior arts by presenting, first, a heat and oxidation resistive high strength material having a heat and oxidation resistive coating layer that has anti-thermal shock, anti-corrosion, and anti-oxidation properties along with excellent adhesive property to the surface of a heat resistive high strength substrate made of carbon and, second, a production method thereof.
  • the first feature of the present invention relates to a heat and oxidation resistive high strength material having a heat and oxidation resistive coating layer on a carbon substrate, comprising a SiC type coating on top of the carbon substrate, a ZrO 2 type ceramic coating on top of the SiC type coating, and an Ir type coating on top of the ZrO 2 type ceramic coating.
  • SiC type coating either the carbon concentration decreases continuously from the carbon substrate to the ZrO 2 type ceramic coating or a mixture layer of a SiC type coating material and a substrate material is formed between a part of the ZrO 2 type ceramic coating side and the carbon substrate.
  • the second feature of the present invention relates to a mixture layer of a SiC type coating material and a ZrO 2 type ceramic coating material formed between the SiC type coating and the ZrO 2 type ceramic coating of the first feature of the present invention.
  • the third feature of the present invention relates to the mixture layer of the SiC type coating material and the ZrO 2 type ceramic coating material of the second feature of the present invention in which the mixture ratio continuously changes from the SiC type coating towards the ZrO 2 type ceramic coating.
  • the fourth feature of the present invention relates to a mixture layer of a ZrO 2 type ceramic coating material and an Ir type coating material formed between the ZrO 2 type ceramic coating and the Ir type coating of the first feature of the present invention.
  • the fifth feature of the present invention relates to the mixture layer of the ZrO 2 type ceramic coating material and the Ir type coating material of the fourth feature of the present invention in which the mixture ratio continuously changes from the ZrO 2 type ceramic coating towards the Ir type coating.
  • the sixth feature of the present invention relates to the SiC type coating of the first, second, third, fourth, or fifth feature of the present invention comprising SiC as the main constituent with a part or a whole of the vacant space filled with Al 2 O 3 , ZrO 2 , Y 2 O 3 , or SiO 2 , or combinations thereof.
  • the seventh feature of the present invention relates to the ZrO 2 type ceramic coating of the first, second, third, fourth, fifth, or sixth feature of the present invention comprising ZrO 2 as the main constituent along with more than one from the group consisting of Y 2 O 3 , MgO, and CaO.
  • the eighth feature of the present invention relates to the carbon substrate of the first, second, third, fourth, fifth, sixth, or seventh feature of the present invention being made from a carbon fiber reinforced carbon.
  • the ninth feature of the present invention relates to a heat and oxidation resistive high strength material comprising a carbon substrate layered with a heat and oxidation resistive coating layer, which has a SiC type coating formed by a chemical vapor reaction method, and has a ZrC or a HfC coating formed by a chemical vapor deposition method, and has a ZrO 2 type ceramic coating layered on top of the ZrC or the HfC coating, and has an Ir type coating layered on top of the ZrO 2 type ceramic coating.
  • the tenth feature of the present invention relates to a method for producing a heat and oxidation resistive high strength material, which has a carbon substrate layered with a heat and oxidation resistive coating layer on the surface, comprising the steps of forming a SiC type coating on the surface of the carbon substrate, forming a ZrO 2 type ceramic coating on top of the SiC type coating, and forming an Ir type coating on top of the ZrO 2 type ceramic coating by an electron beam vapor deposition method.
  • the eleventh feature of the present invention relates to a method for producing a heat and oxidation resistive high strength material, which has a carbon substrate layered with a heat and oxidation resistive coating layer on the surface, comprising the steps of forming a SiC type coating on the surface of the carbon substrate, forming a ZrO 2 type ceramic coating on top of the SiC type coating, and forming an Ir type coating on top of the ZrO 2 type ceramic coating by using a method that uses simultaneously an electron beam vapor deposition method and ion beam irradiation.
  • the twelfth feature of the present invention relates to a method of the eleventh feature of the present invention, wherein the acceleration voltage of ion beam is within 1 to 50 kV and the main element that comprises the ion beam is either oxygen or argon.
  • a carbon fiber reinforced carbon material is utilized, which is made of a matrix of carbons where carbon fibers fill the interstices.
  • this carbon fiber reinforced carbon material in placing this carbon fiber reinforced carbon material in the oxidative atmosphere at 2000° C. as an environmental induced damage and heat resistive material, reliability of the coating layer against environmental induced damage becomes a very important consideration. Important factors for this consideration are the heat resistivity, anti-oxidation ability, structural design, and adhesion. The following describes the coating layer of the present invention.
  • a coating layer structure of the present invention form a heat resistive ceramic coating with excellent adhesion to the substrate and also a high melting point metallic coating with an oxygen barrier function on the surface layer exposed to the oxidative atmosphere.
  • a middle level layer ceramic coating has a reaction suppressing function on the heat resistive ceramic coating and the high melting point metallic coating.
  • SiC is a good choice in regard to the heat resistive ceramic coating formed on top of the substrate of the carbon fiber reinforced carbon, having excellent mechanical characteristics and chemical stability at high temperatures.
  • This SiC coating is formed by the chemical vapor reaction method and the chemical vapor deposition method, depending on the function of purpose. That is, as SiC, which is formed on top of the substrate directly, needs to have a high adhesion force, the chemical vapor reaction method is used such that the metallic silicon vapor is reacted with and bonded to the carbon substrate, and this process produces SiC; thereby adhesion to the substrate can be promoted; and because the coating is a multiporous body, it is effective in relaxing thermal shocks.
  • this coating can be ZrC or HfC.
  • ZrC is desirable because it is compatible with the ZrO 2 coating.
  • microcracks form across the thickness of the SiC coating, which is formed by the chemical vapor reaction method and the chemical vapor deposition method, because of thermal stress caused by the differences in thermal expansion between the substrate and the coating. Therefore, there is a possibility of oxygen penetrating into the substrate through these microcracks and damaging the substrate. For this reason, sealing the microcracks is effective in preventing penetration. Concerning the materials for this purpose, Al 2 O 3 , ZrO 2 , Y 2 O 3 , or SiO 2 or combinations thereof, having heat resistivity, can be used.
  • the filling process of these materials involves a sol/gel method; that is, it involves filling or painting TEOS, MAP, butoxyl zirconium, tetra-n-butoxyl zirconium, or tris-n-butoxyl yttrium into the cracks and firing the product.
  • the SiC type coating can be produced which has excellent heat resistivity and great adhesion to the substrate of the carbon fiber reinforced carbon.
  • Ir is desirable, in addition to being a high melting point metal that has excellent heat and oxidation resistivity at 2000° C., as it has the oxygen barrier function that prevents the impregnation of oxygen into the internal parts of the heat resistive ceramics coating or the carbon fiber reinforced carbon. That is, within the platinum metal VIII family, Os, Ir, and Ru have heat resistivity at 2000° C., but Ir has the highest melting point temperature among this group at 2447° C. and has the least amount of evaporative abrasion in the oxidative atmosphere.
  • the other high melting point metals such as Ta, W, and Zr are subject to abrasion in the oxidative atmosphere or oxidative reaction, and hence, they are not desirable for the stated purpose of the present invention. From these, high melting point metal coating can be had, which has excellent heat and oxidation resistivity.
  • a coating structure in which Ir of a high melting point metallic coating is directly placed on the SiC of a high heat resistive ceramic coating on top of the substrate, reacts to form IrSi, which has a low melting point of 1380° C., and therefore, the purpose of the present invention cannot be realized. For this reason, it is necessary to place a ceramic coating middle layer between SiC and Ir that does not react with either of these coatings at 2000° C. and that still has excellent heat and oxidative resistivity. In the present invention the purpose is accomplished by having a middle layer ceramic coating.
  • ZrO 2 which has a non-reactive function with either SiC or Ir and has heat resistivity, anti-thermal shock property, anti-oxidation property, and low thermal conduction as a ceramic, is selected. Additionally, it is effective to add Y 2 O 3 , MgO, or CaO as stabilizers in preventing phase change of ZrO 2 .
  • Al 2 O 3 the other representative ceramics
  • the ZrO 2 type coating is found appropriate for its heat resistivity in conjunction with the SiC high heat resistivity ceramic coating and Ir high melting point metallic coating and for its non-reactive function.
  • the method for producing the ZrO 2 type ceramic coating and the Ir type coating becomes an important consideration. That is, in consideration of violent thermal shocks and history of heating/cooling that can be received by the ZrO 2 type ceramic coating formed on top of the SiC type coating and by the Ir type coating formed on top of the ZrO 2 type ceramic coating, a coat forming technology of the present invention producing excellent adhesion at the interface of each coating is presented. Another feature of the coat forming technology of the present invention, in order to control thermal stress and the characteristics of each coating, is the excellent control of the elements in coating whereby various constituents are continuously changed easily from the surface to the inner surface and are not uniformly distributed within the coating.
  • ion beam was determined to be best suited for the purpose. The method involves irradiating the substrate with an ion beam and vaporizing the ZrO 2 type or Ir type materials by the electron beam vapor deposition method, which is suitable for melting high melting point heat resistant ceramics.
  • An ion beam is a high density energy source, but this energy must be applied only on the outermost surface.
  • the coating layer that is formed becomes a chemical compound. This is because the energy imparted by the irradiation of ion beam has the same effect as the preheating of the substrate to a high temperature for the instance of deposition. Furthermore, there is a feature that the constituents of this compound can be freely selected by controlling the quantity of deposition and the quantity of energy of the ion beam irradiation.
  • the acceleration voltage of the dynamic ion beam mixing it becomes possible to produce a sputtering phenomenon associated with ion irradiation. Through this, sputtering cleaning can be conducted. Therefore, after cleaning the surface of the SiC type coating, if the ZrO 2 type coating is formed on top of it, the adhesion of the ZrO 2 type coating can be improved because there are no impurity at the interface.
  • the production method of the present method invention on top of the C/C substrate having a SiC type coating of several tens of microns to several hundreds of microns thick formed by the chemical vapor reaction method and the chemical vapor deposition method, first, an ion beam irradiation and a ZrO 2 type material deposition are conducted simultaneously to form a mixing layer. Second, the energy of ion beam is made small or reduced to zero and the ZrO 2 type material is deposited to form a fine ZrO 2 type ceramic coating.
  • ion beam irradiation and Ir type material deposition are conducted simultaneously to form the mixing layer.
  • the energy of ion beam is made small or reduced to zero and the Ir type material is deposited to form a fine Ir type coating.
  • a mixing layer is formed between the SiC type coating and the ZrO 2 type ceramic coating, or between the ZrO 2 type ceramic coating and the Ir type coating, and an extremely good adhesion can be obtained even when the product is heated to a high temperature range.
  • the heat and oxidation resistive coating layer produced by the production method of the present method invention has a high reliability in terms of materials near the origin of destruction induced by thermal stress, and hence peeling associated with destruction is made difficult.
  • Concerning the production method of the present method invention it is desirable to have oxygen ions for ion beam. The reason for this is that, when the coating is heated to a high temperature and melted by the electron beam in the case for the ZrO 2 type material deposition, oxygen is released to form ZrO 2-x , and hence it is desirable to have an oxygen ion beam that can resupply the oxygen under the condition of obtaining ZrO 2 in as close to stoichiometric value as possible.
  • the speed of the response of the energy associated with the irradiation of ion beam can be noted. That is, when the ion beam is turned on, the energy becomes immediately suitable for coat forming, and when the ion beam is turned off or reduced, the energy is immediately extinguished. This type of rapid response is extremely difficult to achieve by the vacuum internal heating of a large structural product.
  • an environmentally induced damage resistant coating layer having excellent heat resistivity and adhesive property on the substrate of the carbon fiber reinforced carbon can be obtained.
  • FIG. 1 illustrates a cross-sectional view of the heat and oxidation resistive high strength material of the present invention.
  • FIG. 2 illustrates a cross-sectional view of the heat and oxidation resistive high strength material of the present invention.
  • FIG. 3 illustrates a cross-sectional view of the heat and oxidation resistive high strength material of the present invention.
  • FIG. 4 shows a graph which indicates the constituent density of the heat and oxidation resistive high strength material of the present invention.
  • FIG. 5 is a schematic of a high frequency thermal plasma irradiation instrument for the oxidation experiment.
  • FIG. 6 indicates a cross-sectional view of the structure of a gas turbine.
  • FIG. 7 is an expanded view of a part of the turbine blade of FIG. 6.
  • FIG. 8 is an expanded view of a part of the turbine blade of FIG. 6.
  • FIG. 9 is an expanded view of a part of the combustor of FIG. 6.
  • an environmentally induced damage resistant coating layer that is heat and oxidation resistant is formed as shown in FIG. 1.
  • This environmentally induced damage resistant coating layer is made up of three coatings which are a SiC type coating 2, a ZrO 2 type coating 4, and an Ir coating 6.
  • the dimension of the substrate 1 is 25 mm on the side and 5 mm in thickness, and the environmentally induced damage resistant coating layer is formed on the entire surface of this substrate 1.
  • the SiC type coating is formed after washing and drying the substrate 1.
  • a SiC type coating 2A of 60 microns in thickness is formed by the chemical vapor reaction method with coke power at the processing temperature of 2000° C. and the surface residue is cleaned by honing.
  • 120 microns in average of a SiC type coating 2B is formed on top of the SiC type coating 2A by the plasma chemical vapor deposition method.
  • the process requirements are that the processing gases, SiCl 4 , CH 4 , and H 2 , be used at the processing temperature of 1400° C., the processing pressure be 4 Torr, the applied voltage be 1200 V, and the applied current be 10 A (discharge area approximately 3600 cm 2 .
  • the ZrO 2 type coating 4 is formed on the surface of the substrate having the SiC type coating 2 by the ion beam mixing method comprising the ion beam source and the deposition source.
  • the deposition source is the electron beam with the 10 kW output power.
  • the material for the deposition source is ZrO 2 -6% Y 2 O 3 and the material for the ion beam source is oxygen ions.
  • the coat formation involves irradiating the surface of the SiC type coating 2 with an Ar ion beam (acceleration voltage 10 kV) and sputter cleaning the surface associated with the Ar ions.
  • the pressure in the formation chamber in this case is 2 ⁇ 10 -5 Torr, and the temperature is set to 75° C.
  • the passage of the gas of the ion beam source is closed and ZrO 2 -6% Y 2 O 3 is deposited.
  • the thickness of the coating was brought to 70 microns by controlling the coating formation monitor.
  • the pressure in the formation chamber is controlled to 5 ⁇ 10 -5 Torr and the substrate temperature is controlled to 1000° C. By this, a fine ZrO 2 type coating without pores or holes is made.
  • the Ir coating 6 is formed in the same process as described above on the surface of the substrate having the ZrO 2 type coating 4 and the SiC type coating 2.
  • the coat formation involves irradiating the surface of the ZrO 2 type coating 4 with the oxygen ion beam (acceleration voltage 10 kV) and sputter cleaning the surface associated with the oxygen ions.
  • the pressure in the formation chamber is 2 ⁇ 10 -5 Torr, and the temperature is set to 75° C.
  • the irradiation of the oxygen ions is stopped and Ir is deposited. In this state, the thickness is brought to 30 microns while monitoring with the coating formation monitor.
  • the pressure in the formation chamber is controlled to 2 ⁇ 10 -5 Torr and the substrate temperature is controlled to 1000° C. By this, a fine Ir type coating 4 without pores is achieved.
  • a SiC coating 2A and a SiC coating 2B is formed by the same method with the same specifications as in the embodiment 1.
  • a visual inspection of this surface reveals several microcracks of 5 microns at maximum. Hence, these microcracks are sealed after the SiC coating is formed.
  • the sealing involves using TEOS and MAP; the product is submerged into these liquids, and after about 100 mg of weight increase is incorporated, it is heated at a low temperature of 400° C. in air, and following this, it is heated at a high temperature of 1000° C. From these processes, a SiC type coating 2 comprising the SiC coating 2A, the SiC coating 2B, and the microcrack seal 2C is made, as shown in FIG. 2.
  • a ZrO 2 type coating 4 and an Ir coating 6 are formed by the same method with the same specifications as in the embodiment 1.
  • This test product was tested for durability, as in the embodiment 1, and the result was the same as in the embodiment 1.
  • An environmentally induced damage resistant coating layer having resistance to heat and oxidation is formed as shown in FIG. 3.
  • a SiC type coating 2 is formed by the same method with the same specifications as in the embodiment 2.
  • this test product is irradiated by an Ar ion beam (acceleration voltage 10 kV) and the surface according to the Ar ion is sputter cleaned.
  • the pressure inside the coating chamber is 2 ⁇ 10 -5 Torr at this point and the substrate temperature is 75° C.
  • the source for the ion beam is changed to oxygen, an oxygen ion beam (acceleration voltage 10 kV) is irradiated on the test product while depositing ZrO 2 -6%Y 2 O 2 .
  • the deposition and the irradiation are conducted and by monitoring the coating thickness, the thickness is made to 70 microns.
  • the internal pressure of the coat forming chamber is 8 ⁇ 10 -5 Tort and the temperature is controlled to 1000° C.
  • a mixing layer 3 having a mixture of SiC of the SiC type coating surface and ZrO 2 -6%Y 2 O 3 of the deposition material is formed, and the thickness of this layer is measured to be 0.1 micron.
  • 70 microns of a ZrO 2 -6%Y 2 O 3 layer is formed. In this way a fine ZrO 2 type coating 4 that does not have pores is constructed.
  • an Ir coating 6 is formed on the surface of the product that has the SiC type coating 2 and the ZrO 2 type coating 4.
  • an oxygen ion beam (acceleration voltage 10 kV) is irradiated on the surface of the ZrO 2 type coating 4, and the surface according to the oxygen ions is sputter cleaned.
  • the pressure inside the coating chamber is 2 ⁇ 10 -5 Torr and the substrate temperature is 75° C.
  • Ir is deposited while irradiating the surface with the oxygen ions.
  • the coating thickness is monitored to a thickness of about 0.5 micron by irradiating and depositing. After this, the gas passage for the ion beam source is shut off, and only the Ir deposition is conducted.
  • the thickness was increased to 30 microns by monitoring the thickness formation.
  • the internal pressure of the coat forming chamber is 3 ⁇ 10 -5 Torr and the temperature is controlled to 1000° C.
  • a mixing layer 5 of a mixture of ZrO 2 and Ir of the deposition material is formed on top of the ZrO 2 type coating surface, and the thickness of this particular layer is made to about 0.1 micron.
  • an Ir coating of 30 microns is formed, and a fine Ir type coating 4 without pores is achieved.
  • test product 14 is fixed on a holding fixture 15, and this is placed inside a closed vessel 16 which is evacuated by a vacuum pump 17.
  • a high frequency electricity source 11 and a high frequency coil 10 the atmospheric gas supplied by a gas supply control system 12 is excited to generate a thermal plasma 13, and this is irradiated on the test product 14.
  • the number 18 designates a shutter.
  • This instrument has a high frequency electricity source of 50 kW output, and supplies oxygen to produce oxygen plasma, and inside this instrument the test product 14 is placed and is heated for 20 minutes at a temperature between 1300° C. and 2000° C. The result was evaluated by the change in weight.
  • an environmentally induced damage resistant coating layer of heat and oxidation resistivity is formed.
  • a SiC type coating 2 is formed by the same method with the same specifications as in the embodiment 2.
  • this test product is irradiated by an Ar ion beam (acceleration voltage 10 kV) and the surface according to the Ar ion is sputter cleaned.
  • the pressure inside the coating formation chamber is 2 ⁇ 10 -5 Torr at this point and the substrate temperature is 75° C.
  • the source for the ion beam is changed to methane, and a carbon ion beam (acceleration voltage 10 kV) is irradiated on the test product while depositing SiC.
  • the deposition and the irradiation are simultaneously conducted and by monitoring the coating thickness, the thickness is made to 5 microns.
  • the beam scanning of electron beam is controlled to form a gradient element coating of 10 microns having the quantity of SiC and ZrO 2 -6%Y 2 O 3 continuously changing inversely over the thickness.
  • the deposition of ZrO 2 -6%Y 2 O 3 and the irradiation of the oxygen ion beam are simultaneously conducted to build up a ZrO 2 coating of 50 microns.
  • the internal pressure of the coat forming chamber is 8 ⁇ 10 -5 Torr and the temperature is controlled to 1000° C.
  • the gradient element coating which has a continuous changing mixture of ZrO 2 -6%Y 2 O 3 of the deposition material and SiC of the SiC type coating surface, and the ZrO 2 -6%Y 2 O 3 only layer are formed. And these fine layers are devoid of holes or pores.
  • the beam scanning of electron beam is controlled to form a gradient element coating of 10 microns having the quantity of ZrO 2 -6%Y 2 O 3 and the quantity of Ir continuously changing inversely over the thickness.
  • only Ir is deposited to build up an Ir coating of 30 microns.
  • the internal pressure of the coat forming chamber is 3 ⁇ 10 -5 Torr and the temperature is controlled to 1000° C.
  • the gradient element coating which has a continuous changing mixture of ZrO 2 -6%Y 2 O 3 of the deposition material and the Ir only coating are formed. And these fine layers are devoid of holes or pores.
  • the heat and oxidation resistive high strength material of the carbon fiber reinforced carbon having the environmentally induced damage resistant coating layer is shown to be extremely durable at high temperatures.
  • FIG. 6 shows an example of the land machine composite material of the present invention utilized in a rotational part and the surrounding parts of a gas turbine shown in a cross-sectional view.
  • the numeral 21 indicates a turbine disc, 22 a turbine blade, 23 a turbine stocking, 24 a turbine spacer, 25 a distant piece, 26 a compressor disc, 27 a compressor blade, 28 a compressor stocking bolt, 29 a compressor stub shaft, 30 a turbine disc, 31 a central hole, 32 a turbine nozzle, 33 a combustor, 34 a compressor nozzle, 35 a liner, 36 a diaphragm, and 37 a shroud.
  • FIG. 7 shows the detail of the turbine blade 22 of FIG. 6, and in the present embodiment, this turbine blade is made of the heat and oxidation resistive high strength material of the embodiment 1 of the present invention.
  • the turbine of the prior art is made of metallic material or metallic material coated with ceramic; and to reduce the temperature of the blade, it is cooled by compressed air.
  • the cooling method involves suspending the inner structure of the turbine and cooling the inner structure, and after this, directing a cooled air from the end of the blade to the burning gas, and furthermore, cooling in a film like manner the outer surface of the gas turbine that is abraded by the burning gas blowing out from the small holes on the surface of the turbine blade. Because these procedures necessitate a large amount of compressed air, they invite inefficiency of the turbine.
  • the cooling means is directed toward the burning gas, this lowers the temperature of the burning gas.
  • the outer surface of the turbine blade that is subject to abrasion by the burning gas is made from the carbon fiber reinforced carbon which has high heat strength as well as excellent durability. That is, the carbon fiber reinforced carbon of the substrate of the turbine blade is a long fiber chain structure (three dimensional structure) of determined construction that is a matrix of long carbon fiber chains; and on this surface, the part indicated by the slanted line in FIG. 7, the heat and oxidation resistive coating layer of the present invention is placed.
  • the result of burning the turbine model based on this gas turbine blade 22 for 100 hours showed no damages on the environmentally induced damage resistant coating layer, and hence, no damages were detected on the carbon fiber reinforced carbon of the substrate.
  • the turbine blade of the present embodiment causes no reduction of the burning gas temperature, and because the usage of the amount of compressed air can be reduced, efficiency of the turbine is not sacrificed.
  • FIG. 8 shows the detail of the turbine nozzle 32 of FIG. 6.
  • this turbine nozzle is made with the heat and oxidation resistive high strength material of the present invention featured in the embodiment 2.
  • the carbon fiber reinforced carbon that is to be the basis for the turbine nozzle is a long fiber chain structure (three dimensional structure) of determined construction that is a mesh of long carbon fiber chains, and the heat and oxidation resistive coating layer of the present invention is placed on the blade surface 38 indicated by the mesh part in FIG. 8 and the gas pass parts 39 and 40.
  • the result of burning the turbine model based on this gas turbine nozzle for 100 hours showed no damages on the environmentally induced damage resistant coating layer, and hence, no damages were detected on the carbon fiber reinforced carbon of the substrate.
  • FIG. 9 shows a cross-sectional view of a combustor part of the combustor 33 shown in FIG. 6, which is constructed with the heat and oxidation resistive high strength material of the present invention.
  • Burning occurs inside the cylindrical structure of the combustor part. Therefore, the inside of the combustor part is subject to high temperature abrasion.
  • the combustor part of the prior art, having metallic structure, is cooled by compressed air to reduce the high temperature. However, this invites cooling of the burning gas because this method introduces cooling means into the burning gas.
  • the combustor part structure of the present embodiment it is not necessary to employ cooling in a film like manner of the surface torched by the burning gas because the surface is coated by the heat and oxidation resistive high strength material, which has excellent thermal and oxidation resistivity. Furthermore, by blowing in compressed air into the space 42 between the structure 41 of Ni based thermal resistant alloy and the heat and oxidation resistive high strength material 43, the constructed structure can be more effectively cooled, and there is no need to mix compressed air with the burning gas.
  • the turbine blade of the present embodiment causes no substantial reduction of the burning gas temperature.
  • the heat and oxidation resistive high strength material of the present invention does not crack or peel even in the high temperature/oxidative atmosphere since it is made in the manner as described above. Also, in accordance with the present method invention, the production of the heat and oxidation resistive high strength material of special characteristics can be facilitated.
  • the product coated with these materials are extremely strong against high temperatures.
  • the light weight heat and oxidation resistive high strength product of the present invention which has an open space for cooling, since it is possible to flow in cooling means into the open space in the high temperature/oxidation atmosphere, a reduction of the temperature of the structure can be achieved and durability can be increased.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Ceramic Products (AREA)
  • Chemical Vapour Deposition (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
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WO2001061066A1 (fr) * 2000-02-17 2001-08-23 Anatoly Nikolaevich Paderov Procede d"application de revetements de protection sur des pieces en alliages refractaires
US6323052B1 (en) * 1997-08-13 2001-11-27 Mitsubishi Chemical Corporation Compound semiconductor light emitting device and method of fabricating the same
US6443700B1 (en) * 2000-11-08 2002-09-03 General Electric Co. Transpiration-cooled structure and method for its preparation
US6677618B1 (en) 1998-12-04 2004-01-13 Mitsubishi Chemical Corporation Compound semiconductor light emitting device
US6793968B1 (en) * 1999-03-04 2004-09-21 Siemens Aktiengesellschaft Method and device for coating a product
US6902692B2 (en) * 2000-07-27 2005-06-07 General Electric Company Process for making a fiber reinforced article
US20050277535A1 (en) * 2002-09-11 2005-12-15 Wilke Werner H Method for covering a plastic cup with a print substrate
WO2007012775A2 (fr) * 2005-07-28 2007-02-01 Saint-Gobain Centre De Recherches Et D'etudes Europeen Support de cuisson pour ceramiques et procede d'obtention
US7229675B1 (en) 2000-02-17 2007-06-12 Anatoly Nikolaevich Paderov Protective coating method for pieces made of heat resistant alloys
US20080107810A1 (en) * 2006-11-03 2008-05-08 Kim Min T Method for forming anti-corrosion and anti-oxidation coating layer on high-temperature components of gas turbine fuel additive
US20160208371A1 (en) * 2013-08-27 2016-07-21 Agency For Science, Technology And Research Method of treating a thermal barrier coating
US10595428B2 (en) 2014-05-20 2020-03-17 The Boeing Company Integrated wiring system for composite structures

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WO1997001436A1 (en) * 1995-06-26 1997-01-16 General Electric Company Protected thermal barrier coating composite with multiple coatings
EP1173657B1 (de) * 1999-03-09 2003-08-20 Siemens Aktiengesellschaft Turbinenschaufel und verfahren zur herstellung einer turbinenschaufel
FR2925044B1 (fr) * 2007-12-13 2010-03-12 Snecma Propulsion Solide Procede de realisation d'une couche de carbure refractaire sur une piece en materiau composite c/c.
DE102010041786A1 (de) 2010-09-30 2012-04-05 Siemens Aktiengesellschaft Gasturbinenbauteil
DE102012205055B4 (de) 2012-03-29 2020-08-06 Detlef Haje Gasturbinenbauteil für Hochtemperaturanwendungen, sowie Verfahren zum Betreiben und Herstellen eines solchen Gasturbinenbauteils
CN102807394B (zh) * 2012-08-17 2013-11-06 航天材料及工艺研究所 一种炭质材料表面制备高温抗氧化涂层的方法
US10060019B2 (en) * 2012-11-16 2018-08-28 The Boeing Company Thermal spray coated reinforced polymer composites
RU2712557C2 (ru) * 2015-02-27 2020-01-29 Пиротек, Инк. Переливной перекачивающий насос из материала с улучшенными свойствами
CN105294143B (zh) * 2015-11-02 2017-09-05 中国航天空气动力技术研究院 梯度化防热材料及其制备方法
CN111116228A (zh) * 2019-11-18 2020-05-08 中南大学 一种抗烧蚀ZrC-HfC/SiC双层复相陶瓷涂层的制备方法
CN111485220A (zh) * 2020-05-28 2020-08-04 西北工业大学 一种SiC纳米线增韧化学气相沉积ZrC涂层及制备方法
CN112457056B (zh) * 2020-11-30 2021-09-10 中南大学 一种成分梯度可控多元超高温陶瓷改性c/c复合材料的制备方法
CN116589305B (zh) * 2023-07-19 2023-09-19 中南大学 一种含超高温陶瓷复合涂层的碳陶复合材料及其制备方法

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US6323052B1 (en) * 1997-08-13 2001-11-27 Mitsubishi Chemical Corporation Compound semiconductor light emitting device and method of fabricating the same
US6677618B1 (en) 1998-12-04 2004-01-13 Mitsubishi Chemical Corporation Compound semiconductor light emitting device
US6793968B1 (en) * 1999-03-04 2004-09-21 Siemens Aktiengesellschaft Method and device for coating a product
WO2001061066A1 (fr) * 2000-02-17 2001-08-23 Anatoly Nikolaevich Paderov Procede d"application de revetements de protection sur des pieces en alliages refractaires
US7229675B1 (en) 2000-02-17 2007-06-12 Anatoly Nikolaevich Paderov Protective coating method for pieces made of heat resistant alloys
US6902692B2 (en) * 2000-07-27 2005-06-07 General Electric Company Process for making a fiber reinforced article
US6443700B1 (en) * 2000-11-08 2002-09-03 General Electric Co. Transpiration-cooled structure and method for its preparation
US20050277535A1 (en) * 2002-09-11 2005-12-15 Wilke Werner H Method for covering a plastic cup with a print substrate
FR2889087A1 (fr) * 2005-07-28 2007-02-02 Saint Gobain Ct Recherches Support de cuisson pour ceramiques et procede d'obtention
WO2007012775A3 (fr) * 2005-07-28 2007-03-22 Saint Gobain Ct Recherches Support de cuisson pour ceramiques et procede d'obtention
WO2007012775A2 (fr) * 2005-07-28 2007-02-01 Saint-Gobain Centre De Recherches Et D'etudes Europeen Support de cuisson pour ceramiques et procede d'obtention
US20090081106A1 (en) * 2005-07-28 2009-03-26 Saint-Gobain Centre De Recherches Et D'et Firing support for ceramics and method for obtaining same
US8685357B2 (en) 2005-07-28 2014-04-01 Saint-Gobain Centre De Recherches Et D'etudes Europeen Firing support for ceramics and method for obtaining same
US20080107810A1 (en) * 2006-11-03 2008-05-08 Kim Min T Method for forming anti-corrosion and anti-oxidation coating layer on high-temperature components of gas turbine fuel additive
US20160208371A1 (en) * 2013-08-27 2016-07-21 Agency For Science, Technology And Research Method of treating a thermal barrier coating
US10595428B2 (en) 2014-05-20 2020-03-17 The Boeing Company Integrated wiring system for composite structures

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JP3136385B2 (ja) 2001-02-19
DE69409074T2 (de) 1998-07-02
EP0657404A1 (en) 1995-06-14
EP0657404B1 (en) 1998-03-18
DE69409074D1 (de) 1998-04-23
JPH07157384A (ja) 1995-06-20

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